Vehicle pillar reinforcement using additive manufacturing

ABSTRACT

The present disclosure relates to a method including forming a plurality of components via an additive manufacturing process to define an integral reinforcement member and reinforcing a corner member of a vehicle pillar with the integral reinforcement member. The plurality of components include a first component and a second component. The first and second components formed integrally as a single unit. The first component and the second component include a functionally graded material that is deposited on the corner member via the additive manufacturing process.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 17/067,448, filed Oct. 9, 2020 and titled “VEHICLE PILLAR REINFORCEMENT USING ADDITIVE MANUFACTURING”, the contents of which are incorporated herein by reference in its entirety.

FIELD

The present disclosure generally relates to reinforcement of a vehicle pillar using additive manufacturing.

BACKGROUND

Vehicles typically include vertical supports, such as vehicle pillars. The vehicle pillars can support windscreens, roofs, and windows. The vehicle pillars are generally spaced in a fore-aft direction of the vehicle. For example, some vehicle pillars may include an A-pillar, a B-pillar, a C-pillar, and a D-pillar, arranged moving from a front of the vehicle to a rear of the vehicle. In vehicle pillars, joints can affect strength, rigidity, and load bearing capacity of the vehicle. In addition, joints of vehicle pillars can provide structural attachment to other components of the vehicle, for example liftgate hinges, roof racks, and liftgate cylinders. It is desirable to reinforce vehicle pillars to enhance structural performance and torsional stiffness of the vehicle. Typically, various casting methods are used to manufacture reinforcement structures, such as a pillar cap reinforcement.

SUMMARY

The present disclosure relates to additively manufactured reinforcement member. Additive manufacturing helps in reducing the overall weight of the reinforcement member and helps in consolidating various attachment points on the reinforcement member.

In one example, embodiment, a vehicle pillar includes a corner member, and a reinforcement element coupled to the corner member. The reinforcement element includes a first component, and a second component, where the first and second components are formed integrally as a single unit.

In one example embodiment, a vehicle pillar reinforcement includes a first component having a first attachment joint, and a second component having a second attachment joint, where the first and second components are formed as a single unit via an additive manufacturing process.

In one example embodiment, a method includes forming a plurality of components via an additive manufacturing process to define an integral reinforcement member, and reinforcing a vehicle pillar member with the reinforcement member.

In one form, the present disclosure relates to a method including forming a plurality of components via an additive manufacturing process to define an integral reinforcement member and reinforcing a corner member of a vehicle pillar with the integral reinforcement member. The plurality of components include a first component and a second component. The first and second components formed integrally as a single unit. The first component and the second component include a functionally graded material that is deposited on the corner member via the additive manufacturing process.

In variations of the method of the above paragraph, which can be implemented individually or in any combination: the method further includes directly depositing a material on the vehicle pillar, the depositing forming the integral reinforcement member on the vehicle pillar; directly depositing includes depositing via laser direct energy deposition; forming a plurality of components via an additive manufacturing process includes at least one of directed energy deposition, wire fed arc weld, powder-laser directed energy deposition, or cold spray; each of the first component and the second component includes at least one integral joint element configured to secure at least one of a hinge element and a strut to the integral reinforcement member; the functionally graded material includes a first material having a variable density gradient; the functionally graded material includes a first material and a second material; the first material is fused with the second material to generate a dynamic gradient; the dynamic gradient includes at least one of a compositional gradient or a densification gradient; and the integral reinforcement member includes one or more cavities that provide wiring access.

In another form, the present disclosure relates to a method including forming a plurality of components via an additive manufacturing process to define an integral reinforcement member and reinforcing a corner member of a vehicle pillar with the integral reinforcement member. The plurality of components include a first component, a second component, and a third component. The first, second, and third components formed integrally as a single unit. The first component and the second component include a functionally graded material that is deposited on the corner member via the additive manufacturing process. Each of the first component and the second component includes at least one integral joint element configured to secure at least one of a hinge element and a strut to the integral reinforcement member.

In variations of the method of the above paragraph, which can be implemented individually or in any combination: the functionally graded material includes a first material having a variable density gradient; the functionally graded material includes a first material and a second material; the first material is fused with the second material to generate a dynamic gradient; the dynamic gradient includes at least one of a compositional gradient or a densification gradient; the integral reinforcement member includes one or more cavities that provide wiring access; the third component is a hollow tubular structure; the third component includes an integral joint element configured to secure a vehicle part to the integral reinforcement member; and the integral joint element of the third component is a clip.

In yet another form, the present disclosure relates to a method including forming a plurality of components via an additive manufacturing process to define an integral reinforcement member and reinforcing a corner member of a vehicle pillar with the integral reinforcement member. The plurality of components include a first component, a second component, and a third component. The first, second, and third components formed integrally as a single unit. The first component and the second component include a functionally graded material that is deposited on the corner member via the additive manufacturing process. Each of the first component, the second component, and the third component includes at least one integral joint element configured to secure at least one of a hinge element, a strut, and a clip to the integral reinforcement member. The functionally graded material includes a first material and a second material, the first material is fused with the second material to generate a dynamic gradient.

DRAWINGS

FIG. 1A is a perspective view of a vehicle body structure, according to an embodiment of the present disclosure.

FIG. 1B is a detailed view of a corner member of the vehicle body structure of FIG. 1 , according to an embodiment of the present disclosure.

FIG. 2 is a top perspective view of a reinforcement member, according to an embodiment of the present disclosure, coupled to the corner member of FIG. 1B.

FIG. 3 is a bottom perspective view of the reinforcement member coupled to the corner member shown in FIG. 2 .

FIG. 4 is a top perspective view of the reinforcement member coupled to the corner member, illustrating various vehicle components coupled to the reinforcement member using a plurality of attachment joints, according to an embodiment of the present disclosure.

FIG. 5 is a top view of a reinforcement member of FIG. 2 formed via additive manufacturing, according to an embodiment of the present disclosure.

FIG. 6 is a bottom perspective view of the reinforcement member formed via additive manufacturing shown in FIG. 5 .

FIG. 7 is a cross sectional view of the reinforcement member formed via additive manufacturing shown in FIG. 5 .

FIG. 8 is a top perspective view of a vehicle pillar reinforcement coupled to a vehicle pillar, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures or methods associated with vehicles have not been shown or described in detail to inhibit unnecessarily obscuring descriptions of the embodiments.

FIGS. 1A and 1B illustrate a vehicle with vehicle pillars and an example corner member of one of the vehicle pillars. In particular, FIG. 1A illustrates a portion of a side of a vehicle body structure 100. Although not shown for the sake of clarity of illustration and description, an opposite side of the vehicle body structure 100 is generally similar to the one shown in FIG. 1A. The vehicle body structure 100 may be, for example, a Body-in-White (BIW) structure of a Sport Utility Vehicle (SUV), a Crossover Utility Vehicle (CUV), or any other vehicle having a liftgate. The vehicle body structure 100 includes a pair of rear door openings 102, a pair of front door openings 104, and a liftgate opening 106. The openings 102, 104 and 106 may each be sized to receive a suitable rear door, front door, and liftgate, respectively. The vehicle body structure 100 further includes a plurality of vehicle pillars regions 110 such as an A-pillar region 110 a, a B-pillar region 110 b, a C-pillar region 110 c, and a D-pillar region 110 d. While the illustrated vehicle body structure 100 is configured for a vehicle having four doors and one liftgate, it is contemplated that in embodiments with other configurations, the locations, presence, or number of doors and liftgate may be varied, changed, or omitted.

The vehicle body structure 100 includes a roof 112, a rear quarter window opening 114, a quarter window member 116, and a roof cross member 118. The rear quarter window opening 114 is sized and shaped to receive a rear quarter window (not shown for the sake of clarity of description and illustration). The quarter window member 116 extends along an upper portion of the rear quarter window opening 114, and between pillar regions (e.g., the C-pillar region 110 c and the D-pillar region 110 d). The roof cross member 118 extends along an upper portion of the liftgate opening 106 and between opposing pillar regions (e.g., the D-pillar region 110 d and the opposing D-pillar region that is not shown for the sake of clarity of illustration and description). The D-pillar region 110 d is positioned proximate to the liftgate opening 106 and the rear quarter window opening 114. The D-pillar region 110 d further includes a corner member 120 (shown in FIG. 1B), described in detail below.

The corner member 120, shown in FIG. 1B, is formed via a suitable manufacturing process such as stamping, and is positioned at one end of the D-pillar region 110 d, adjacent to the roof 112. The corner member 120 provides a rigid joining surface for the D-pillar region 110 d with the roof cross member 118 and the quarter window member 116. The corner member 120 includes a first end 120 a that couples to the roof cross member 118, a second end 120 b that couples to the D-pillar region 110 d, and a third end 120 c that couples to the quarter window member 116. In the illustrated embodiment, the corner member 120 is coupled to the roof cross member 118, the D-pillar region 110 d, and the quarter window member 116 via spot welding. Optionally, any other suitable coupling techniques and structures may be utilized such as, for example, fastening.

The corner member 120 further includes a first peripheral wall 122, a second peripheral wall 124 and a base plate 126. The first and second peripheral walls 122, 124 protrude away from the base plate 126 and define a substantially arcuate shape. In one example embodiment, the arcuate shape of the corner member 120 may be substantially congruent to a shape of a curved corner region of the liftgate opening 106. The arcuate shape formed by the first peripheral wall 122 and the second peripheral wall 124 defines a recess 128 that is sized and shaped to receive a reinforcement element or a reinforcement member (shown in FIGS. 2, 3, and 4 and described in more detail below), which is positioned on the base plate 126. In some embodiments, including embodiments described herein, the reinforcement element is fabricated via one or more additive manufacturing techniques to reduce overall weight of the reinforcement element. In some embodiments, the reinforcement member is manufactured separately and later coupled to the base plate 126 of the corner member 120.

In some embodiments, the corner member 120 may operate as a platform or substrate for directly manufacturing the reinforcement member onto the corner member 120. For example, in some embodiments, direct additive manufacturing may be used to fabricate the reinforcement member onto the corner member 120, which can provide manufacturing and assembly efficiencies, including enhance part consolidation.

FIGS. 2 and 3 are isometric views of a reinforcement member 200 coupled to the corner member 120. FIG. 4 is an illustration of various vehicle components coupled to the D-pillar region 110 d using various attachment joints of the reinforcement member 200.

As shown in FIG. 2 , the reinforcement member 200 includes a first component 202 a and a second component 202 b. In one or more embodiments, the reinforcement member 200 also includes a third component 202 c. The first component 202 a, the second component 202 b and the third component 202 c (collectively referred to as components 202) are hollow tubular structures and are integrally formed as a single unit via one of the additive manufacturing processes described in more detail below. In the illustrated example embodiment, the first, second and third components 202 a, 202 b and 202 c extend to the first, second and third ends 120 a, 120 b, and 120 c of the corner member 120, respectively. As shown in FIGS. 2-4 , the third component 202 c extends angularly with respect to the first component 202 a and the second component 202 b. The first, second and third components 202 a, 202 b and 202 c together form a “Y” shaped reinforcement member 200.

As shown in FIG. 3 , the third component 202 c includes walls 204 a, 204 b. The walls 204 a, 204 b define a periphery of the third component 202 c of the reinforcement element 200 and are each angularly oriented to define a recess 206. Similarly, the first component 202 a includes walls 204 c, 204 d, and the second component 202 b also includes walls 204 e, 204 f. The walls 204 c, 204 d, 204 e, 204 f, again, define a periphery of each of the first and second components 202 a, 202 b and form respective recesses 207, 209.

The walls 204 a-f (collectively referred to herein as walls 204) may also define one or more cavities or access openings 208. The access openings 208 may provide access to, for example, welding equipment, wires, or other components, such that these structures or components may extend through the first, second and third components 202 a, 202 b and 202 c of the reinforcement member 200.

As shown in FIG. 2 , the first component 202 a, the second component 202 b and the third component 202 c include one or more joint elements 210 a-d (also referred to as attachment joints 210) that protrude outwardly from outer surfaces of the first and second components 202 a, 202 b. The joint elements 210 provide attachment elements for coupling various vehicle parts to the reinforcement member 200.

FIGS. 2 and 4 illustrate in more detail, the coupling of the joint elements 210 to various vehicle components. For example, the first component 202 a includes a first joint element 210 a to couple the reinforcement member 200 to a hinge element 212. The second component 202 b includes a second joint element 210 b to couple the reinforcement member 200 to a strut 214.

The reinforcement member 200 includes additional joint elements, such as, for example, a clip 210 c on the third component, and a hook 210 d on the first component 202 a. The hook 210 d may couple with a quarter window cover 216. The clip 210 c may couple to a roof cover (not shown for clarity of illustration and description). In some embodiments, the type and position of the joint elements 210 may be changed, added, omitted, or generally varied.

In contrast to typical D-pillar joints, in the embodiments described herein, a single reinforcement member 200 can be provided with integrally formed multiple attachment joint elements to couple to various parts of the vehicle body structure 100, which enhances part consolidation.

The reinforcement member 200, according to the present disclosure, is manufactured directly on a member of the vehicle pillar 110 such as the corner member 120, as described in conjunction with FIGS. 5 and 6 . Specifically, the reinforcement member 200 is manufactured directly onto the base plate 126 of the corner member 120 using at least one of an additive manufacturing technique or process, such as, for example, laser direct energy deposition. In some embodiments, the reinforcement member 200, may alternatively, be manufactured separately using at least one of an additive manufacturing (AM) process, such as, for example, material extrusion, 3-D printing, material jetting, powder bed fusion, Directed Energy Deposition (DED) and later coupled to the corner member 120 using any suitable coupling structures. In an embodiment, where metal extrusion process is used to manufacture the reinforcement member 200, a material in a filament form can be drawn through a nozzle, heated and then extruded and deposited onto the build platform in a layer-by-layer process. In an embodiment, metal extrusion 3D printers can be used to manufacture the reinforcement member 200. The metal extrusion 2D printer may be cartesian type 3D printer, where the nozzle may move in an X, Y direction, whereas a build platform may move in a Z-direction.

In an embodiment, where material jetting process is used to manufacture the reinforcement member 200, a material in the form of liquid droplets may be dispensed from multiple printheads. The material may comprise photosensitive polymer, which hardens on exposure to UV light to build the reinforcement member 200 layer-by-layer.

In an embodiment, where powder bed fusion process is used to manufacture the reinforcement member, the process may use a laser or an electron beam to sinter, melt and fuse the powder particles together while tracing a cross-section of the reinforcement member 200. On completion of a first layer, the powder dispensing unit may spread a new layer of powder onto the build platform and the printing may continue for subsequent layers, until the reinforcement member 200 is manufactured.

In an embodiment, where DED process is used to manufacture the reinforcement member 200, a nozzle may hold a material in a wire form, also referred to as a feed, which moves across multiple axes. An electron beam projector may melt the feed as the electron beam projector moves across while tracing geometry of the reinforcement member 200.

As noted above, the reinforcement member 200 may be later coupled to the corner member 120 using any suitable coupling structures. For example, the reinforcement member 200 may be coupled to the base plate 126 and positioned in the recess 128 of the corner member 120 via welding, fastening, or other suitable coupling structures.

FIGS. 5, 6, and 7 illustrate detailed views of the reinforcement member 200 as it is being formed via additive manufacturing. As shown in FIGS. 5-7 , the plurality of components 202 of the reinforcement member 200 are manufactured as an integral part of the reinforcement member 200 and configured to integrally form the attachment joints 210 a, and 210 b. Referring to FIGS. 5 and 6 , the design and pattern of the plurality of components 202 include elements of biomimicry to form a biomimicry mesh 218 for load path optimization. The reinforcement member 200 is manufactured directly on the corner member 120, using one of the additive manufacturing processes, such as directed energy deposition (DED), wire fed arc weld, powder-laser directed energy deposition, or cold spray.

In an embodiment where the DED process is used to manufacture the reinforcement member 200 directly on the corner member 120, as described above, a nozzle holds a material in a wire form, which is known as a feed, which moves across multiple axes, and an electron beam projector melts the feed as the electron beam projector moves across while tracing the object geometry.

In an embodiment where the wire fed arc weld process is used to manufacture the reinforcement member 200, an arc welding process is used to 3D print a metallic reinforcement member 200. In the wire fed arc weld process, a metal wire may be melted using an electric arc as a heat source.

In an embodiment where the cold spraying additive manufacturing is used to manufacture the reinforcement member 200, the reinforcement member 200 is built on the corner member 120, for example. During this process, fine powder particles flow in a high velocity compressed gas stream, and upon the contact on a substrate or backing plate, deform and bond together creating a layer. Moving the nozzle over a substrate repeatedly, a deposit is built layer-by-layer, to form the reinforcement member 200 on the corner member 120.

In an embodiment where the powder-laser directed energy deposition process is used to manufacture the reinforcement member 200, a laser beam may form a melt pool on a metallic substrate, into which powder is fed. The powder is thereafter melted to form a deposit that is fusion bonded to the substrate. In this embodiment, the substrate can take the form of the corner member 120 and the powder may comprise stainless steel to form the reinforcement member 200 on the corner member 120.

In one embodiment, the reinforcement member 200 and the integrally formed plurality of components 202 are manufactured via functionally graded additive manufacturing (FGAM) using a functionally graded material (FGM). The functionally graded materials (FGM) can comprise composite materials with gradual variations in their compositions and structures throughout their volume. FGM can be selected to develop gradient components with specific graded properties at different locations.

In one example, the FGM includes a first material and a second material. The first material and second material can have different density gradients, e.g., properties of the first and second materials can be different. Further, in one embodiment, the first material is fused with the second material to generate a dynamic gradient. The reinforcement member 200 and the integrally formed plurality of components 202 manufactured using the dynamic gradient may incorporate at least one of a compositional gradient or a densification gradient. Thus, the reinforcement member 200 and the integrally formed plurality of components 202 can have variable properties at different locations. For example, a portion of the plurality of components 202 may be configured to have a higher compositional gradient or a densification gradient at select locations requiring higher torsional stiffness, while another portion of the plurality of components 202 may have a lower compositional gradient or a densification gradient which experience less torsional stresses.

As shown in FIGS. 5-7 , as the reinforcement member 200 is formed via additive manufacturing, the plurality of components 202 include three end members 220 a, 220 b and 220 c. The end members 220 a, 220 b and 220 c are located at the three ends of the first, second and third components 202 a, 202 b and 202 c, respectively of the plurality of components 202. The end members 220 a, 220 b and 220 c are perpendicular to the biomimicry mesh 218 of the plurality of components 202, and may act as platforms or supports for manufacturing the plurality of components 202. Again, as shown in FIGS. 2-4 , upon forming of the reinforcement member 200 via one or more of the additive manufacturing processes described herein, the reinforcement member 200 will include integrally formed plurality of components 202 and joint elements. Further, as described above, in some embodiments, the material of additive manufacturing may comprise stainless steel or FGM. In some embodiments, the material of additive manufacturing may comprise high-strength steel, titanium, composites, aluminum, for example.

FIG. 8 illustrates the reinforcement member 200 formed directly on the corner member 120 of a pillar region (e.g., the D-pillar region 110 d) of a vehicle 300 by using one or more of the additive manufacturing processes described herein.

As described above, the reinforcement member 200 can be formed via directly depositing an additive manufacturing material on corner member 120. In some embodiments, the additive manufacturing can include depositing a combination of two or more materials, for example, a functionally graded material. The functionally graded material can include a first material and a second material, where the first material can have a variable density gradient. The first material can be fused with the second material to generate a dynamic gradient. The dynamic gradient can include at least one of a compositional gradient or a densification gradient. In some embodiments, the dynamic gradient of the functionally graded material can be varied, for example, to enhance load path optimization when depositing on the corner member 120. Again, in this manner, a plurality of components, e.g., components 202, can be formed integrally, with any desired number of joint elements, e.g., joint elements 210.

Although in the example embodiments described above, the reinforcement member 200 or the vehicle pillar reinforcement 200 is coupled to a corner member 120 of a pillar region (e.g., the D-pillar region 110 d), in other embodiments, reinforcement members or other coupling members or structures can be integrally formed with any of the vehicle pillars 110 (e.g., the A-pillar region 110 a, the B-pillar region 110 b, and the C-pillar region 110 c) via one or more of the additive manufacturing processes described herein. Further, in some embodiments, the one or more of additive manufacturing processes may be used to consolidate two or more vehicle components by integrally forming the two or more vehicle components. Moreover, the various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure. 

What is claimed is:
 1. A method comprising: forming a plurality of components via an additive manufacturing process to define an integral reinforcement member; and reinforcing a corner member of a vehicle pillar with the integral reinforcement member, wherein the plurality of components include a first component and a second component, the first and second components formed integrally as a single unit, and wherein the first component and the second component comprise a functionally graded material that is deposited on the corner member via the additive manufacturing process.
 2. The method of claim 1, further comprising: directly depositing a material on the vehicle pillar, the depositing forming the integral reinforcement member on the vehicle pillar.
 3. The method of claim 2 wherein directly depositing includes depositing via laser direct energy deposition.
 4. The method of claim 1 wherein forming a plurality of components via an additive manufacturing process includes at least one of directed energy deposition, wire fed arc weld, powder-laser directed energy deposition, or cold spray.
 5. The method of claim 1, wherein each of the first component and the second component includes at least one integral joint element configured to secure at least one of a hinge element and a strut to the integral reinforcement member.
 6. The method of claim 1, wherein the functionally graded material includes a first material having a variable density gradient.
 7. The method of claim 1, wherein the functionally graded material includes a first material and a second material.
 8. The method of claim 7, wherein the first material is fused with the second material to generate a dynamic gradient.
 9. The method of claim 8, wherein the dynamic gradient includes at least one of a compositional gradient or a densification gradient.
 10. The method of claim 1, wherein the integral reinforcement member includes one or more cavities that provide wiring access.
 11. A method comprising: forming a plurality of components via an additive manufacturing process to define an integral reinforcement member; and reinforcing a corner member of a vehicle pillar with the integral reinforcement member, wherein the plurality of components include a first component, a second component, and a third component, the first, second, and third components formed integrally as a single unit, wherein each of the first component and the second component includes at least one integral joint element configured to secure at least one of a hinge element and a strut to the integral reinforcement member, and wherein the first component and the second component comprise a functionally graded material that is deposited on the corner member via the additive manufacturing process.
 12. The method of claim 11, wherein the functionally graded material includes a first material having a variable density gradient.
 13. The method of claim 11, wherein the functionally graded material includes a first material and a second material.
 14. The method of claim 13, wherein the first material is fused with the second material to generate a dynamic gradient.
 15. The method of claim 14, wherein the dynamic gradient includes at least one of a compositional gradient or a densification gradient.
 16. The method of claim 11, wherein the integral reinforcement member includes one or more cavities that provide wiring access.
 17. The method of claim 11, wherein the third component is a hollow tubular structure.
 18. The method of claim 11, wherein the third component includes an integral joint element configured to secure a vehicle part to the integral reinforcement member.
 19. The method of claim 18, wherein the integral joint element of the third component is a clip.
 20. A method comprising: forming a plurality of components via an additive manufacturing process to define an integral reinforcement member; and reinforcing a corner member of a vehicle pillar with the integral reinforcement member, wherein the plurality of components include a first component, a second component, and a third component, the first, second, and third components formed integrally as a single unit, wherein each of the first component, the second component, and the third component includes at least one integral joint element configured to secure at least one of a hinge element, a strut, and a clip to the integral reinforcement member, wherein the first component and the second component comprise a functionally graded material that is deposited on the corner member via the additive manufacturing process, and wherein the functionally graded material includes a first material and a second material, the first material is fused with the second material to generate a dynamic gradient. 